Conformable track assembly for a robotic crawler

ABSTRACT

A suspension system for a lightweight robotic crawler is disclosed. The suspension system provides for mounting of a flexible endless track thereon. The suspension system includes a forward guide and a rearward guide around which the endless track can be looped. A deflector positioned between the forward guide and the rearward guide downwardly deflects a ground-engaging portion of the endless track to form a peaked area. The peaked area can support the lightweight robotic vehicle allowing alteration of a distribution of load over the ground-engaging portion of the endless track with respect to a supporting surface.

RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 11/985,324, filed Nov. 13, 2007, which claims the benefit ofU.S. Provisional Patent Application No. 60/858,805, filed Nov. 13, 2006in the United States Patent and Trademark Office, and entitled,“Conformable Track Assembly For A Robotic Crawler,” which application isincorporated by reference in its entirety herein.

FIELD OF THE INVENTION

The present invention relates to small, unmanned ground roboticvehicles. More particularly, the present invention relates to asuspension system for mounting a flexible endless track to support alightweight robotic vehicle.

BACKGROUND OF THE INVENTION AND RELATED ART

Unmanned robotic vehicles can be deployed in a variety of applicationsand environments, including for example, search and rescue, militaryoperations, and industrial operations. Unmanned robotic vehicles canhelp to avoid the need to expose humans to hazardous environments, suchas unstable buildings, military conflict situations, and chemically,biologically, or nuclear contaminated environments.

Unmanned robotic vehicles face many challenges when attempting mobility.Terrain can vary widely, including for example, bumpy or smoothsurfaces, firm or soft ground, loose and shifting materials, etc. Forsmall robotic vehicles, the challenges become even greater. A vehicleoptimized for operation in one environment may perform poorly in otherenvironments.

The use of endless tracks are known to provide a good compromise whichallows a robotic vehicle to accommodate a large variation in terraintypes while maintaining relatively good traction and maneuverability.For example, tank-like vehicles using a pair of parallel endless trackscan provide high stability in some environments.

Tracked vehicles are typically steered using skid steering. In skidsteering, the tracks on opposite sides of the vehicle are moved atdifferent rates. Skid steering can be inefficient, as portions of thetracks move perpendicular to the direction of travel. There can besignificant friction opposing this sideways motion. For longer tracks,greater force must be applied to overcome this friction. Theinefficiency of skid steering also increases for tighter radius turns.The inefficiency of skid steering is at a peak when there is no netforward movement of the vehicle, only rotation around a central pivotpoint. A sharp turning radius can also result in significant stress onthe vehicle suspension components due to the lateral movement. Forlightweight robotic vehicles which tend to have limited drive poweravailable, sharp turns may therefore be difficult or impossible toobtain.

SUMMARY OF THE INVENTION

The present invention includes a suspension system for a flexibleendless track that helps to overcome problems and deficiencies inherentin the prior art. In one embodiment, the suspension system includes aframe, on which a forward guide, rearward guide, and at least onedeflector are mounted. An endless track can be looped around the forwardguide and rearward guide. The deflector downwardly deflects aground-engaging portion of the endless track between the forward guideand the rearward guide to form a peaked area. The deflector isconfigured as a full load-bearing component capable of altering adistribution of load over the ground-engaging portion of the endlesstrack with respect to a supporting surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully apparent from the followingdescription and appended claims, taken in conjunction with theaccompanying drawings. Understanding that these drawings merely depictexemplary embodiments of the present invention they are, therefore, notto be considered limiting of its scope. It will be readily appreciatedthat the components of the present invention, as generally described andillustrated in the figures herein, can be arranged and designed in awide variety of different configurations. Nonetheless, the inventionwill be described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 illustrates a perspective view of a suspension system formounting a flexible endless track according to an exemplary embodimentof the present invention;

FIG. 2 illustrates a perspective view of a lightweight robotic vehiclehaving a suspension system in accordance with another embodiment of thepresent invention;

FIG. 3 illustrates a side view of a suspension system for mounting aflexible endless track according to another exemplary embodiment of thepresent invention;

FIG. 4 illustrates a side view of a suspension system for mounting aflexible endless track according to yet another exemplary embodiment ofthe present invention; and

FIG. 5 illustrates a flow diagram of a method for supporting alightweight robotic vehicle on an endless track according to anembodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following detailed description of exemplary embodiments of theinvention makes reference to the accompanying drawings, which form apart hereof and in which are shown, by way of illustration, exemplaryembodiments in which the invention may be practiced. While theseexemplary embodiments are described in sufficient detail to enable thoseskilled in the art practice the invention, it should be understood thatother embodiments may be realized and that various changes to theinvention may be made without departing from the spirit and scope of thepresent invention. Thus, the following more detailed description of theembodiments of the present invention is not intended to limit the scopeof the invention, as claimed, but is presented for purposes ofillustration only and not limitation to describe the features andcharacteristics of the present invention, to set forth the best mode ofoperation of the invention, and to sufficiently enable one skilled inthe art to practice the invention. Accordingly, the scope of the presentinvention is to be defined solely by the appended claims.

The following detailed description and exemplary embodiments of theinvention will be best understood by reference to the accompanyingdrawings, wherein the elements and features of the invention aredesignated by numerals throughout.

With reference to FIG. 1, shown is an illustration of a suspensionsystem for mounting a flexible endless track thereon to support alightweight robotic vehicle according to a first exemplary embodiment ofthe present invention. Specifically, FIG. 1 illustrates the suspensionsystem 10 as including a frame 12 having a forward guide 14 and arearward guide 16 coupled thereto. An endless track 18 can be loopedaround the forward guide and the rearward guide. A deflector 20 iscoupled to the frame between the forward guide and the rearward guide.The deflector downwardly deflects the ground-engaging portion 22 of theendless track to form a peaked area 24. The deflector is a load-bearingcomponent, capable of supporting the lightweight robotic vehicle. Thedeflector is thus capable of altering a distribution of loading over theground-engaging portion of the endless track with respect to asupporting surface. In other words, the deflector can be extended orretracted to cause different distributions of the weight of the roboticvehicle over the ground-engaging portion of the endless track. Forexample, the deflector can be extended to cause the weight of the robotto be substantially concentrated on the portion of the ground-engagingportion under the deflector. As another example, the deflector can beretracted to cause the weight of the robot to be distributedsubstantially over the entire ground-engaging portion of the endlesstrack. Of course, various other weight distributions in between theseextremes are also possible. The actual distribution of weight over theground-engaging portion of the endless track will be a function of theamount of deflection of the deflector and the properties of the surfaceon which the lightweight robotic vehicle is operated. The orientation ofthe lightweight robotic vehicle can thereby be altered with respect to asupporting surface by operation of the deflector.

Operation of a lightweight robotic vehicle using a suspension system inaccordance with an embodiment of the present invention will now bedescribed. FIG. 2 illustrates an exemplary tandem configuration of alightweight robotic vehicle 26 using two tracked units 28 a, 28 b, eachhaving a suspension system 10 as described above. The tracked units arelinked together by an articulated arm 30. For example, commonly-ownedU.S. Provisional Non-provisional patent application Ser. No. 11/985,322,entitled, “Serpentine Robotic Crawler,” filed Nov. 13, 2007 andincorporated in its entirety by reference herein, describes a serpentinerobotic crawler in which the suspension system of the present inventioncan be used.

The lightweight robotic vehicle 26 is operated on a supporting surface32. When operated over a firm area 33 of the supporting surface, thepeaked area 24 a of the endless track helps to support substantially allof the weight of tracked unit 28 a. In contrast, when operated over asoft area 34 of the supporting surface, the peaked area 24 b of theendless track will sink into the supporting surface, and the weight oftracked unit 28 b is distributed over the ground-engaging portion 22 bof the endless track. It will be appreciated that the operation of theendless tracks 18 a, 18 b and articulated arm 30 can be coordinated tomaintain the lightweight robotic vehicle balanced on the peaked areas ofthe endless tracks.

When a lightweight robotic vehicle using the suspension system 10 isoperated on a firm surface, the deflector lifts the lightweight roboticvehicle up so that most of the endless track is off the supportingsurface. Hence, only the small area of the endless track near the peakedarea 24 is in contact with the supporting surface. This helps to reducefriction when skid steering is performed, allowing for a tighter turningradius as compared to a conventional endless track, which provides aflat ground-engaging surface. Turning performing is accordingly morecomparable to that of a wheeled vehicle than a tracked vehicle.

When the lightweight robotic vehicle is operated on a soft surface, alarger ground-engaging area of the endless track is in contact with thesupporting surface. This provides better fraction than a wheeledvehicle. Turning radius is not greatly reduced, however, as the softsurface provides relatively little friction to lateral movement of thetrack. Hence, the suspension system provides an improvement in turningradius over a conventional endless track on firm surfaces, whileretaining the fraction advantages of the endless track on soft surfaces.

Various alternate arrangements of the components of the suspension 10are possible. Referring back to FIG. 1, the forward guide 14, rearwardguide 16, and deflector 20 can be rollers rotatably mounted to the frame12. The forward guide, rearward guide, and deflector can be mounted infixed positions on the frame relative to each other, although this isnot essential. Alternately, the forward guide, the rearward guide, orthe deflector can be movable, for example to help maintain constanttension in the track.

The deflector 20 can also include a load-sensing element (not shown).For example, the load-sensing element can be a load cell, strain gauge,pressure sensor, or the like as is known in the art. During operation ofthe lightweight robotic vehicle, the deflector may support a varyingportion of the lightweight robotic vehicle's weight, and thus aload-sensing element on the deflector can provide useful information forcontrol of the lightweight robotic vehicle. For example, a lightweightrobotic vehicle may be in a tank-like configuration where parallelendless tracks are disposed on each side of the vehicle. Each endlesstrack can include a deflector and associated load-sensing element. Whenthe vehicle is at risk of tipping sideways, the load sensed on onedeflector will greatly exceed the other deflector. Corrective action canthen be taken.

In accordance with another embodiment of the present invention, asillustrated in FIG. 3, a suspension system 40 can include a moveabledeflector assembly 42. For example, the deflector 20 can be mounted to apiston arm 44 that is driven up and down by hydraulic cylinder 46. Thiscan allow the amount of downward deflection of the endless track to beadjusted during operation of the lightweight robotic vehicle. Forexample, when operating on hard surface, the deflector may be displaceddownward to provide a strongly curved peaked area to enable tightturning. When operating on a soft surface, the deflector may bedisplaced upward to provide a flatter ground-engaging area to maximizetraction. Optionally, track tensioning components (not shown) can beincluded to maintain proper tension of the endless track as thedeflector is moved up or down. The hydraulic cylinder is capable ofgenerating enough force to enable supporting the full weight of thelightweight robotic vehicle. For example, for a lightweight roboticvehicle which weighs 20 pounds (or less), downward deflector force of 20pounds (or more) is sufficient to allow the full weight of thelightweight robotic vehicle to be carried by the peaked area of thetrack. Since the deflector is capable of supporting the full weight ofthe lightweight robotic vehicle, it will be appreciated that heaviervehicles require a more robust deflector design. Accordingly, it isexpected that lightweight robotic vehicles are more adaptable toembodiments of the present invention than large, heavy vehicles. Moreparticularly, while many different deflector configurations will besuitable for supporting a lightweight robotic vehicle, a singledeflector capable of supporting a large tank, for example, appearssomewhat impractical.

In accordance with another embodiment of the present invention, asillustrated in FIG. 4, a suspension system 50 can include multipledeflectors 52 a, 52 b, 52 c coupled to the frame 12. The multipledeflectors downwardly deflect the ground-engaging portion of the endlesstrack to form the peaked area into a curved shape. Multiple deflectorscan provide various different profiles, allowing the detailed shape ofthe peaked area to be optimized for particular environments. Forexample, multiple moveable deflectors can be used to dynamically varythe shape of the peaked area during operation, as well as adjust thevertical orientation, or pitch, of the lightweight robotic vehicle.Multiple deflectors can also provide some benefit in allowing the loadof the lightweight robotic vehicle to be distributed over multiplecomponents. As discussed above, the deflectors can include load-sensingelements. Operation of the deflectors may be modified based onmeasurements obtained from the load-sensing elements.

In accordance with another embodiment of the present invention, asillustrated in FIG. 5, a method for supporting a lightweight roboticvehicle on an endless track is shown in flow diagram form. The method,shown generally at 60, includes providing 62 an endless track loopedaround a forward guide and a rearward guide of the lightweight roboticvehicle. For example, various examples of suspension systems having aforward guide and a rearward guide are discussed above. The method alsoincludes deflecting 64 a ground-engaging portion of the endless trackbetween the forward guide and the rearward guide in a downward directionto form a peaked area of the endless track. Various examples ofdeflectors are discussed above. Finally, the method includes supporting66 the lightweight robotic vehicle at least partially by the peaked areaso as to enable changing distribution of load over the ground-engagingportion of the endless track with respect to a supporting surface. Forexample, the lightweight robotic vehicle can be balanced on the peakedarea as discussed above. As another example, the lightweight roboticvehicle can be pivoted on the peaked area to provide a short or zeroradius turn.

Optionally, as discussed above, the method can include operating thelightweight robotic vehicle on a firm surface such that the peaked areaof the endless track supports substantially all of the weight of thelightweight robotic vehicle. This can help to provide short radiusturns. In addition, as discussed above, the method can include operatingthe lightweight robotic vehicle on a soft surface such that the weightof the lightweight robotic vehicle is distributed over theground-engaging portion of the endless track. This can help to providehigh traction.

The method can also include coupling the lightweight robotic vehicle toa second lightweight robotic vehicle, for example as described above.Operation of the coupled lightweight robotic vehicles can be coordinatedto maintain one (or both) of the lightweight robotic vehicles balancedon the peaked area.

Finally, the method can also include moving the deflector up or down.For example, moving the deflector down can create a more strongly peakedarea of the endless track to provide for shorter turning radius. Movingthe deflector up can create a more flat ground-engaging portion of theendless track to provide for better traction.

Summarizing and reiterating to some extent, various endless tracksuspension system configurations have been described which providevarious benefits over the prior art. For example, deflecting a portionof the ground-engaging surface of the endless track to form a peakedarea can provide a tight turning radius for a lightweight roboticvehicle operated over a firm surface. Multiple and/or moveabledeflectors can be included to allow varying the shape of the peakedarea. A lightweight robotic vehicle using an embodiment of the presentinvention can provide improved turning radius without sacrificing thetraction benefit provided by the large ground-engaging portion of anendless track.

The foregoing detailed description describes the invention withreference to specific exemplary embodiments. However, it will beappreciated that various modifications and changes can be made withoutdeparting from the scope of the present invention as set forth in theappended claims. The detailed description and accompanying drawings areto be regarded as merely illustrative, rather than as restrictive, andall such modifications or changes, if any, are intended to fall withinthe scope of the present invention as described and set forth herein.

More specifically, while illustrative exemplary embodiments of theinvention have been described herein, the present invention is notlimited to these embodiments, but includes any and all embodimentshaving modifications, omissions, combinations (e.g., of aspects acrossvarious embodiments), adaptations and/or alterations as would beappreciated by those in the art based on the foregoing detaileddescription. The limitations in the claims are to be interpreted broadlybased the language employed in the claims and not limited to examplesdescribed in the foregoing detailed description or during theprosecution of the application, which examples are to be construed asnon-exclusive. For example, in the present disclosure, the term“preferably” is non-exclusive where it is intended to mean “preferably,but not limited to.” Any steps recited in any method or process claimsmay be executed in any order and are not limited to the order presentedin the claims. Means-plus-function or step-plus-function limitationswill only be employed where for a specific claim limitation all of thefollowing conditions are present: a) “means for” or “step for” isexpressly recited in that limitation; b) a corresponding function isexpressly recited in that limitation; and c) structure, material or actsthat support that function are described within the specification.Accordingly, the scope of the invention should be determined solely bythe appended claims and their legal equivalents, rather than by thedescriptions and examples given above.

1. A lightweight robotic vehicle having tandem endless tracks supportedon conformable suspension systems, comprising: at least two framescoupled in tandem by an active, actuatable articulated linkage arm, eachframe comprising: a forward guide coupled to the frame and configured toreceive a looped portion of the endless track around the forward guide;a rearward guide coupled to the frame and configured to receive a loopedportion of the endless track around the rearward guide; and at least onedeflector operable with the frame between the forward guide and therearward guide, the at least one deflector being configured todownwardly deflect a ground-engaging portion of the endless trackbetween the forward guide and the rearward guide to form a peaked areaconfined between the forward guide and the rearward guide, whereinmovement and pose of the lightweight robotic vehicle is at leastpartially controlled by the articulated linkage arm, and wherein thedeflectors of each of the at least two frames are selectively engageableto support the associated frames simultaneously or individually at leastpartially on the respective peaked areas in response to variable surfaceconditions.
 2. The robotic vehicle of claim 1, wherein the articulatedlinkage arm comprises a multi-degree of freedom linkage arm having aseries coupled combination of at least seven actuated joints.
 3. Therobotic vehicle of claim 1, wherein the deflector is selectivelyengageable to deflect the ground-engaging portion of the endless trackin response to changing surface conditions.
 4. The robotic vehicle ofclaim 1, wherein the at least two endless tracks and the articulatedlinkage arm are operable to maintain at least one frame balanced on thepeaked area of the associated endless track.
 5. The robotic vehicle ofclaim 1, further comprising a plurality of deflectors coupled to theframe in positions between the forward guide and the rearward guide andconfigured to downwardly deflect the ground-engaging portion of theendless track to form the peaked area into a curved shape.
 6. Therobotic vehicle of claim 1, wherein the endless track is flexible. 7.The robotic vehicle of claim 1, wherein at least one of the forwardguide and rearward guide is movable relative to the other to maintainconstant tension of the endless track.
 8. The robotic vehicle of claim1, wherein the deflector further comprises a moveable deflector assemblyincluding a roller mounted to a piston arm, and with the piston armbeing actuated by a hydraulic cylinder.
 9. The robotic vehicle of claim1, wherein the deflector further comprises a load-sensing elementadapted to relay information about a load acting on the lightweightrobotic vehicle.
 10. The robotic vehicle of claim 9, wherein theload-sensing element is selected from the group consisting of a loadcell, a strain gauge, a pressure sensor and combinations thereof. 11.The robotic vehicle of claim 1, wherein the at least two frames coupledin tandem with an active articulated linkage arm further comprise atleast three frames coupled in tandem with a plurality of activearticulated linkage arms.
 12. A lightweight robotic vehicle havingtandem endless tracks supported on conformable suspension systems,comprising: at least two frames coupled in tandem with an active,actuatable articulated linkage arm, each frame comprising: a forwardguide coupled to the frame and configured to receive a looped portion ofthe endless track around the forward guide; a rearward guide coupled tothe frame and configured to receive a looped portion of the endlesstrack around the rearward guide; and at least one deflector operablewith the frame, the at least one deflector being selectively engageableto deflect the ground-engaging portion of the endless track between theforward guide and the rearward guide to form a peaked area confinedbetween the forward guide and the rearward guide, wherein the deflectorsof each of the at least two frames are selectively engageable to supportthe frames simultaneously or individually at least partially on therespective peaked areas, wherein movement and pose of the lightweightrobotic vehicle is at least partially controlled by the articulatedlinkage arm, and wherein the at least two endless tracks and thearticulated linkage arm are operable to maintain at least one framebalanced on the peaked area of the associated endless track.
 13. Amethod for supporting a lightweight robotic vehicle on tandem endlesstracks, comprising: operating a first endless track looped around aforward guide and a rearward guide of a first frame; operating a secondendless track looped around a forward guide and a rearward guide of asecond frame, the first and second frames being coupled in tandem by anactive, actuatable articulated linkage arm; selectively deflecting atleast one ground-engaging portion of at least one of the first andsecond endless tracks in a downward direction to form a peaked area ofthe endless track confined between the forward guide and the rearwardguide, wherein the first and second frames are simultaneously orindividually supported at least partially on the respective peakedareas; and articulating the articulated linkage arm to establish adesired pose for the lightweight robotic vehicle and to support at leastone of the first and second frames at least partially on the formedpeaked area so as to enable changing distribution of load over theground-engaging portion of the deflected endless track with respect to asupporting surface.
 14. The method of claim 13, further comprisingcoordinating operation of the first endless track and the second endlesstrack and the articulated linkage arm to maintain the lightweightrobotic vehicle balanced on at least one of the peaked areas.
 15. Themethod of claim 13, further comprising coupling the lightweight roboticvehicle to a second lightweight robotic vehicle, and coordinatingoperation of the first and second lightweight robotic vehicles tomaintain the lightweight robotic vehicle balanced on at least one of thepeaked areas.
 16. The method of claim 13, further comprising:selectively deflecting the ground-engaging portions of both the firstand second endless tracks in a downward direction to form peaked areasof both the first and second endless tracks; and coordinating operationof the first and second endless tracks and the articulated linkage armto maintain the robotic vehicle balanced on the peaked areas.
 17. Themethod of claim 13, further comprising operating the robotic vehicle ona firm surface such that the peaked area supports substantially all theweight of the associated frame.
 18. The method of claim 13, furthercomprising operating the robotic vehicle on a soft surface such that theweight of the associated frame is distributed substantially over theground-engaging portion of the endless track.
 19. The method of claim13, further comprising selectively deflecting the ground-engagingportion in an upward direction to create a flat ground-engaging portionof the endless track.
 20. The method of claim 13, further comprisingselectively deflecting the ground-engaging portion along a vertical axisto vary a degree of curvature of the peaked area of the endless track.21. The method of claim 13, further comprising: providing at least oneadditional endless track looped around a forward guide and a rearwardguide of at least one additional frame; and coupling the at least oneadditional frame in tandem with either of the first and second frameswith at least one additional active, actuatable articulated linkage arm,the lightweight robotic vehicle comprising the first, second and atleast one additional frames.